ELAU Automation Solution for Packaging and Production Brochure

The Automation Solution for Packaging and Production Machine

ELAU®

PacDrive MScalable Solutions from a Single Source

This document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr-thorp.com

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completeautomationsolutions


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Automating with the PacDrive® systemContents:System Overview ...................................................................................................... Page 06Controls & HMI ........................................................................................................... Page 10Tools ................................................................................................................................. Page 14Application Software ............................................................................................... Page 24Integrated Servo Motors ....................................................................................... Page 28Servo Drives ................................................................................................................. 2Servo Motors ............................................................................................................... Page 34Field Bus Interfaces ................................................................................................. Page 40Functional Safety ...................................................................................................... Page 46Robotic Solutions ...................................................................................................... Page 50Electrical Components .......................................................................................... Page 56


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Schneider Electric is one of the few companies in the world to offer a full range of products and solutions for energy distribution and management, building automation and engineering, and industrial automation. Schneider Electric’s portfolio includes electrical equipment for production machinery and process technology at every level, from an entire factory to a single production line or an individual machine.

One-stop shopping:Schneider Electric offers a full range of industrial

electrical equipment

A partner for the entire factory


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A Global PartnerWith 126,000 employees and annual sales of EUR 18.3 billion (2008), Schneider Electric is one of the world’s largest companies in its industry sector. Sales and sup-port personnel in 100 countries, 207 production facilities worldwide, and more than 16,000 sales offices form the backbone of a comprehensive network that can provide expert assistance in every location.

EUR 18.3 billion (USD 25 billion) in sales in 2008

126,000 employees in more than 100 countries

207 production facilities worldwide

R&D centers in 25 countries

Schneider Electric in figures:


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Complete automation solutions for production lines and machinesOne-stop shopping: Your single source for an automation platform, motion and field bus com-ponents and sensors, power distribution, and wiring & cabling technology. Schneider Electric offers it all, and it all fits together. With one of the world’s most extensive product portfolios in the field of automation, Schneider Electric places complete solutions at your disposal, based upon ELAU’s PacDrive® automation technology.

Proven in practiceMore than 45,000 machines automated with PacDrive are already in use worldwide, and the number is growing rapidly. The PacDrive system architecture, based upon open hardware and soft-ware standards that do not rely upon a specifi c manufacturer, helps to ensure the security of your

investment and is adaptable to future technologi-cal advances. IEC standards and internationally current IT standards form the cornerstones of an open architecture that also permits the integration of HMI solutions or fi eld bus interfaces as well as devices from other manufacturers.

System Overview

STB TeSys ATV312 ATV71


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The PacDrive automation system:The basis for a complete solution by Schneider Electric for total automa-tion of packaging and production machinery, including robotics

Electrical Components Mechatronic Components

System Overview >>

Ethernet, TCP/IP, OPC, FTP, HTTP, SMS, SMTP

CANopen, Profibus SERCOS II

Magelis HMI Panel

Cx00Scaleable controller

IT/HMI

Logic Motion

FTB

SD328 Preventa MC-4 MC-4 MC-4

PS-5

DB-5

iSHLMTMSHBRS3ILx


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Integrated Motion & Logic Control - A foundation for uniform solutionsFor more than a decade, a central element in the PacDrive solution has been the integration of motion, PLC, and IT functionalities in an automation platform. This allows the creation of fully integrated software structures that enable modular machine designs and reduce engineering times.

Centralized controllers for all machine functionsPacDrive’s digital system architecture is based upon the concept of a centralized controller. Using an IEC 61131-3-compliant machine pro-gram, a single processor performs all control functions, from cartesian and robotic motion to temperature regulation and machine logic. All of the functions run through the centralized controller, from the human-machine interface to motion and device bus communication, to line synchronization and vertical integration.

Basis for simulation and plug-and-playThe centralized controller generates motion data for all servo axes in the system. It also centrally stores relevant system data and equipment-specifi c parameters. This central-ized approach offers decisive advantages. Moves can be tested and simulated in the controller without having to connect real drives. The controller helps to ensure reliable com-munication with every servo axis, including process data and motor status that can be analyzed for different purposes. Servo motors and drives can also be automatically confi g-ured based upon electronic ‘name plates.’ The controller recognizes the motors and drives, and can send the centrally stored parameters to each device for easy commissioning or replacement. Confi gujration of individual drives is a thing of the past.

System Overview >>


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Scalable - from basic to high performanceFrom an individual machine to an entire pro-duction line, one controller can control up to 99 servo axes or up to 30 robots. On the other end of the performance spectrum, the scalable controller family also offers an economical solu-tion for applications with one to three axes. It can even be used as a pure-play PLC or a data concentrator to acquire production data from a packaging line. Users can synchronize up to 40 controllers in real time, a fully integrated solution for entire production lines.

Basis for fully integrated software designsOne of the major advantages of centralized controller designs is a unifi ed software devel-opment environment, with one programming tool to implement all of the functionalities. There is no need for additional tools, some of which might be proprietary. One tool, one program-ming standard, one software structure: This is the key to the groundbreaking approach of modular mechanical engineering, in which mechatronic functions are mapped on reusable software modules. And to eliminate unneces-sary engineering tasks, pre-tested software libraries minimize programming time and ease the way for FDA validation based upon cGMP/GAMP and CFR 21 Part 11.

SERCOS® drive bus

IT

MotionSPS

Motor control

loops

Motor control

loops

Motor control

loops

Setpoint positionControl info

Service Data

Central machine controller

Decentralizedservo drives

Current positionStatus infoService Data

ERP Data

Real-time line synchronization

9921

Ethernet

System Overview >>


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Scalable controller

performanceThe C200 A2, C200 A4, C400 A8, C400 A16, and C600 A99 automation control-lers can be used in a broad range of ap-

plications. Aspects such as the number of axes to be synchronized, data transmission volumes, and the scope of the robotic ele-ments all help determine which controller offers the optimum balance of price and

performance.

Comprehensive controller functionalitiesIn addition to their motion functionality, all Cx00 controllers have an integrated PLC as well as HMI and data interfaces. There is full software compatibility between all of the controllers, with VxWorks as the universal hard real-time operat-ing system. Control can be distributed across a number of continuous, periodic, or event-driven user tasks. Each controller has two integrated cam switch groups, each with 32 cam tracks. The system can allocate up to 255 cams. Up to 32 different positioning or encoder signals can be assigned to each of the two cam switch groups. Cam signals can be sent to a memory cell or to a digital output.

Depending upon the controller type, memory can be up to 256 MB SD/DDR RAM, or 128 or 256 MB NV RAM, with additional compact Flash memory of 128 MB or more. The memory card can be changed out externally, as can the battery. An alphanumeric display shows diagnostic data. All controllers include an inte-grated eight-channel software oscilloscope and a message logger for diagnostics. All controller types are CE and cULus certifi ed.

Five performance classesin two form factors:Scalable controller performance for economical automation solutions.

Functional:The swiveling alphanume-ric display for diagnostic data output covers the memory card bay.

Controls & HMI


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Integrated I/O – externally expandableAll controllers have integrated digital inputs and outputs (except for the C200). The C400 and C600 also have analog inputs and out-puts. Controllers include both standard I/O and high-speed I/O that allow signifi cantly faster responses to events recorded by sensors. Us-ers can increase the number of high-speed I/O by adding external expansion modules with a high-speed communication connection.

The number of standard I/O and encoder con-nections can also be increased via a fi eld bus.

Interfaces and communicationCommunication with the servo drives is over the SERCOS II motion network. Field bus communi-cations via PROFIBUS-DP V1, CAN, CANopen, or Ethernet/IP helps to ensure fl exibility in re-sponding to different technical requirements for customers in Europe, North America and Asia. A 10/100 Base-T Ethernet connection as well as an RS 232 and RS 485 port are standard equip-ment in every controller. The Ethernet connec-tion serves as an interface to the engineering system and the HMI via OPC, ARTI, or Modbus TCP, as well as an open interface for custom-ized communications solutions.

Performance overview:All Cx00 controller types

Controller type C200 A2 C200 A4 C400 A8 C400 A16 C600 A99

Motion Performance Number of synchronizable axes 0-2 0-4 (8) 0-8 0-16 0-99

Number of dynamic electronic cam plates operating in parallel

255

PLC Performance Time required per 1000 bit instructions (µsec) 25 5

Time required per 1000 words (µsec) 50 10

Programmable dynamic cams 255

Cam cycle time (µsec) 1000 250

Number of user tasks, continuous, periodic, or event-driven

Any number, within the system limits

Fast task cycle time (µsec) 1000 250

Communication Integrated motion bus SERCOS II

Integrated Ethernet connection 10/1 00 Base-T, RS 232 and RS 485

Number of integrated fi eld bus interfaces 1 2

Profi bus DP V1, CAN, CANopen, DeviceNet or EtherNet/IP

Housing dimensions Width x Height x Depth (mm) 60 x 240 x 240 104 x 270 x 240

Scalable hardware for 0 to 99 axes All controllers are

software-compatible Unit can be serviced

without a PC, message output on the integrated plaintext display for messages in 5 languages Support for all current

field buses Integrated 8-channel

software oscilloscope and message logger

Controls & HMI >>

Constantly updated data available at www.elau.de/controls Subject to modifications


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Operator interfaces with full graphic display touchscreen panels

In display sizes of 5.7” to 15”, the graphics-capable Magelis® HMI panels with VxWorks® and Windows XP Embedded offer adaptability to operator display requirements. An ARTI driver simplifies the engineering phase by providing direct access to the runtime system variables.

HMI hardware in two basic designsThe fully graphics-capable Magelis XBT TFT HMI panels come in two basic designs: The GT panels, in sizes of 5.7 to 15” with VxWorks, can be seamlessly integrated into the controller solution. They are equipped for the applica-tion with 16 or 32 MB RAM memory. The GTW panels, which are equipped with 8.4” to 15” displays and run with Windows XP Embedded,

are a winning design that features open archi-tecture for running a wide range of software applications. Memory for applications can be expanded from 250 MB to 1 GB. All of the panels have slots for further memory expan-sion. Ethernet, RS 232C and USB interfaces are integrated into all Magelis panels.

The right size for the right display:Magelis HMI panels allow users to create custom-ized solutions with a mini-mum of engineering time

Controls & HMI >>


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Technical Data

Optimal HMI design for ELAU automation solutions Broad range of solu-

tions with VxWorks and Windows versions Direct access to the

controller’s runtime variables

The Vijeo Designer confi guration software can be used to uniformly implement Magelis-based HMI solutions for all equipment. To reduce en-gineering times, an ARTI protocol driver builds a bridge directly from the confi guration tools to the controller application. This provides direct

access to runtime system variables, which can be easily browsed with the confi guration tool. This eliminates the otherwise typical require-ment for yet another defi nition of variables for the HMI application.

Efficient Engineering

Magelis XBT GT Magelis XBT GTW

XBTGT 2330 XBTGT 7340 XBTGTW 450 XBTGTW 750

Display size 5,7“ 15“ 8,4“ 15“

Resolution 320x240 1024x768 800x600 1024x768

Colors 65536 262.144

Operating system VxWorks Windows XP embedded

Application memory 16 MB 32 MB 256 MB to 1 GB 256 MB to 1 GB

Expandable memory 1 x CF slot up to 1 GB

Ethernet 1x10/100 Base T 2x10/100/1000 RJ45

Serial interface 1 1xRS232C 2xRS232C

Serial interface 2 1xRS485

USB interface 1x1.1 Type A Master 2x1.1 Typ A Master 4x2.0 Typ A Master 4+1(on front) x2.0 Type A Master

Direct access:An ARTI protocol driver forms the basis for high speed communications between the HMI panel and the controller, with full ac-cess to the runtime system variables

Ethernet, TCP/IP

Magelis-HMI Vijeo Designer configuration software

Motion-Logic Control:C200 A2, C200 A4,

C400 A8, C400 A16, C600 A99

Controls & HMI >>

Excerpt from the program, complete and constantly updated data available at www.elau.de/HMIs

IT/HMI

Logic Motion

Subject to modifications


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Fully Integrated Tools

Tools

Fully Integrated Engineering: The PacDrive development environment covers every phase of a project, up to and including commission-ing, while diagnostic tools help to ensure a high level of availability in day-to-day operation

A modular software development environment is the basis for efficient engineering with PacDrive. The central element is the EPAS-4 engineering tool, which is used to develop the controller application and for testing and simulation. Other EPAS-4-compatible tools support engineering tasks by providing software tools for human-machine interface, drive design, com-missioning and diagnostics

Controls & DrivesEngineering

HMI

ECAM-4 Vijeo Designer configuration software

EPAS-4


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Commissioning Maintenance& Service

AutoTune

EPAS-4 EPAS-4

PacDrive Diagnostics

All of the tools work together and have the same look and feel. The development environment is ide-ally suited for managing mechatronic design proj-ects, which increasingly integrate the mechanical, hardware, and electronics development into an interdisciplinary process.

Tools >>


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EPAS-4Uniform programming and parameterization

Trace Function:The integrated oscillo-scope in EPAS-4 permits simultaneous plotting and display of up to eight PLC and motion signals, as well as mixed PLC and motion signals with millisecond resolution

Configuration editor:All hardware components and field buses in the solution can be configured and parameterized in an editor. No other tools are required.

Tools >>

new


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Integration of CAN or PROFIBUS DP interfaces:Field bus interfaces, both masters and slaves, can be imported into the controller configuration of a program-ming project and param-eterized using the field bus configurator

Creating a program: Modular machine programs can be created in the IEC languages. Screenshot shows a program written in Ladder Diagram

Tools >>

With its combination of comprehensive func-tionality and proven software tools, the EPAS-4 Automation Toolkit is a powerful programming tool for PacDrive applications. EPAS-4 can be installed on Windows PCs, and its interface has the look and feel of typical Windows applica-tions. Easy navigation between editors and within the libraries help to ensure ease of use and transparency when creating and simulat-ing programs and commissioning with EPAS-4.

EPAS-4 complies with the IEC 61131-3 stan-dard and includes editors as well as debug-gers for all six standard IEC languages.


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Tools >>

EPAS-4 functionality takes all aspects of com-plete automation solutions into account: With the integrated confi guration editor, all of the so-lution’s hardware components and fi eld buses can be confi gured, parameterized, modifi ed, or expanded with a few entries. EPAS-4’s customizable visualization offers assistance in developing, testing, and simulating the control-ler application. Preprogrammed screens are al-ready available for the commissioning process.

Machine programs can be simulated onscreen in EPAS-4 without real drives. An eight-channel software oscilloscope integrated into EPAS-4 permits the simultaneous plotting of up to eight

PLC and motion variables (including mixed variables). During commissioning, the tool’s message logger makes it easy to track down the source of system and user diagnosis messages.

EPAS-4 can be used for all PacDrive II control-ler versions. Machine programs created for one controller type can be automatically converted with a few entries in the integrated Project Con-verter for porting to other PacDrive controllers.

Ladder Diagram

Instruction List

Structured Text

Continuous Function Chart

Function Block

Sequential Function Chart

Uniform programming and parameterization Program simulation

without real axes Hardware configura-

tion and parameterization without additional editors Visualization tool with

preprogrammed commissioning and service screens Simultaneous trace

plotting of PLC and motion signals (software oscilloscope) Diagnostics tool

message loggerr All IEC 61131-3 editors CoDeSys - based Tool


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Vijeo Designer can be used to confi gure all Magelis touchscreen panels, from the small-est 3.8” touchscreen panel up to complex HMI applications for the 15” touchscreen panels. The tool set also includes the ARTI protocol driver so that users can access runtime system variables via the browser. The tool’s graphi-cal editor provides a number of ready-made elements for customizing HMI interfaces. In ad-dition, a graphics library has more than 4,000 predefi ned vector graphics. The integrated recipe maintenance program can manage 256 recipes with 1,024 ingredients in up to 32 recipe groups.

Users can perform periodic or event-driven processing of Java-based procedures to au-tomate operations such as switching screens, mathematical logical calculations, as well as scaling of automatic changes in variable values. The alarm management system is de-signed for up to 9,999 alarms.

Open-source software included:A suggested schematic diagram is easy to modify, simplifies the learning pro-cess for Vijeo Designer and produces fast results

One tool for all panels Pre-defined functions

and graphic elements provide design support Fast solutions with

open-source sample program ARTI driver for browsing

control variables

Tools >>

Vijeo® Designer configuration softwareCustomized design of HMI interfaces

Vijeo Designer:A large number of predefined elements, graphics libraries, recipe and alarm management functions, and an easy to modify suggested sche-matic make HMI develop-ment fast and easy.


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Tools >>

ECAM-4 combines graphical motion and drivetrain design tools for complex multiaxis systems with up to 99 axes. This modular software tool permits highly precise design of the complete system, from the mechanics to calculation of system power requirements. To streamline the engineering process, ECAM-4 includes a library of predefi ned standard mechanical drive confi gurations, simplifi ed motion design with a graphical cam editor, the availability of standard mo-tion profi les (such as the VDI 2143 Library), and the ability to perform harmonic analyses on motion profi les. ECAM-4 also includes tools for calculating energy-saving power regeneration between drives via the DC bus.

Graphical motion design:By cascading editor windows, users can place movement patterns in chronological relationship to one another

Drivetrain designThe predefined applications offer sufficient adaptability for typical power transmis-sion configurations

Multiaxis motion design with virtual or real master axes Use of an unlimited

number of multiseg- ment profiles, such as VDI 2143 profiles or fifth order polynomials Download of motion

functions for all controllers Import of cam tables via

Excel tables Database for servo

motor/drive and gear reduction sizing and selection Predefined applications

such as general loading condition, belt drive, spindle drive, rack-and- pinion drive, and crank drive

Program data and comprehensive results lists provide information for making sound decisions at every step of the process.

ECAM-4Motion and Drivetrain Design


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Using predefi ned default values PacDrive servo drives provide suffi cient performance out of the box for 95% of all applications. For those more critical situations, the AutoTune tool is available free of charge to PacDrive users to calculate the inertial load seen by individual axes. After entering a few limit values, AutoTune measures the feedback from preset signals, then inde-pendently calculates the optimal parameters for stable feedback loops. Optimization can be used to minimize tracking deviation or attenu-ate resonances.

AutoTune makes feedback loop optimiza-tion faster and simpler. Critical axes can be commissioned without the need for control technology expertise. AutoTune is an IEC 61131-compliant program that works in EPAS-4.

Support for calculating the inertial load and drivel parameters for individual axes Can be used to

minimize tracking deviation or resonances Easy to use in EPAS-4

Tools >>

AutoTuneAutomatic optimization of motor control parameters

No resonance

Small tracking deviation

Determining control parameters with AutoTune:For critical applications, auto tuning automatically calculates the inertial loads for individual axes, which can be used to minimize tracking deviation or reso-nances.


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Tools >>

Data management:Tools make it easier to transfer and handle pro-gram and firmware data

Backup converts program data into the data format needed for copying machine programs from the controller’s Flash drive to a PC, and vice versa. The tool’s functionality also includes the creation of CompactFlash cards for Pac-Drive controllers (including bootable cards), along with the VxWorks operating system and fi rmware. An integrated fi rmware assistant also simplifi es the exchange of fi rmware between PacDrive controllers via LAN (IP) or serial port (RS-232).

NetManage identifi es PacDrive controllers within the network and lists these together with their most important data.

With the SERCOS Firmware Assistant, users can exchange servo drive fi rmware via Ethernet as well as via the controller’s serial port. The tool replaces the boot loader for all servo drive versions.

Support tools make it easier for PacDrive users to handle program and fi rmware data and to per-form program version management.

Software tools for data management

Backup NetManageSERCOS Firmware Assistant


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EPAS-4 includes integrated comprehensive diagnostic functionalities. EPAS is not always available, however, if a machine breaks down during production. This is why PacDrive Diag-nostics was developed specifi cally for servic-ing purposes. The tool offers full diagnostic functions, runs independently of EPAS, and is available at no cost to PacDrive users. It can

be used without any programming knowledge. The intuitive program interface allows users to quickly collect all of the necessary service data. Diagnostic information can be displayed upon demand, stored or forwarded directly to technical support. The tool can be used regardless of the fi rmware version.

Simple tool for collecting service-related system data No EPAS-4 license

required Firmware-independent System map of all servo

drive data (drives, mes sage loggers, cam switch group, etc.) Intuitive user interface

Tools >>

DiagnosticsMaintenance without EPAS-4

Topology of the detected SERCOS devices in the event of errors. The affected devices are highlighted

Diagnosis in the event of machine malfunctions:Diagnostics can be used to perform comprehensive system diagnostics even without programming knowledge. The screenshot shows a check of the PLC configuration.


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Application Software – Solutions to counter rising engineering costs

Application Software

Programming without EMs:The user must configure error handling, diagnostic functions, and different operating modes in the machine program.

Programming with template and EMs:The machine program is modular and organized into Equipment Modules (Ems), eliminating the need to integrate inter-faces, operating modes, diagnostic functionalities, or error handling

PacDrive Market

User program

Equipment module

AFB AFB

System Interface System Interface

(AFB + Op-Mode + Diagn. +Error handling + …)

(Application Function Block) (Application Function Block)

PacDrive portion of the pre-pro-

grammed application

User portion of the pre-pro-

grammed application

User program

PacDrive Template(Programming Framework)


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PacDrive’s IEC 61131-3-compliant software development environment includes a large library of Function Blocks as well as a programming template. Library functions are performed by software that has undergone extensive testing and produces direct time savings. The template serves as a tool for creating standardized, modular software, and therefore also improves machine module reusability. The user can decide whether to use only the Function Block library or the template as well.

Function Blocks for a broad spectrum of tasks

ELAU software libraries consist of Function Blocks (known as AFBs, or Application Func-tion Blocks), which map a variety of motion, PLC, visualization, and basic IT functions in pre-programmed software objects. These range from AFBs for universal generation of positioning and motion functions to tempera-ture control. The libraries also contain AFBs for complete mechatronic functions, such as robots, synchronization functions, fi lm unwinds, and seal bars.

All AFBs are IEC 61131-3-compliant. With their simple interfaces, they can be quickly imple-mented to signifi cantly reduce the time and effort required to create a program. In addition, AFBs have been documented and fi eld-tested thousands of times as off-the-shelf software. For users, this translates into increased software quality and simplifi ed certifi cation procedures. New AFBs are constantly being

created to perform tasks rapidly, simply, and in a standardized format.

Example of an AFB:The AFB FlyingShear- RotaryKnife contains the algorithms ´flying shear´ and ´rotary knife´, in con-formance with IEC 61131-3.

Application Software >>


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Creating programs with a template and equipment modules

The PacDrive template enables consis-tently structured programming of individual machines or complete lines. Users can map software modules to the corresponding me-chanical modules on the machine. Just as the mechatronic Function Blocks in a modu-lar machine can be reused for new projects, the relevant parts of the program can also be reused in programs for other machines with minimal programming effort.

The programming template includes core machine functionalities, such as mode control and error handling. It’s important to apply machine modes and error status con-sistently, especially when integrating multiple machines in a production line.

Equipment Modules are the template’s equivalent of the Application Function Blocks which can be used without the template. AFBs become Equipment Modules when

the are implemented within the template, often with other Equipment Modules, to create a cohesive, well structured program. An Equipment Modules also includes the interfaces for error handling, diagnostics and operating modes.

Programming template:Machine programs can be developed by combining Equipment Modules, re-sulting in a modular soft-ware structure that mirrors the machine’s modular, mechatronic design.


MES/ERP Level

Line Level

Machine Level

EquipmentModule Level 2

EquipmentModule Level 1 Grouping Cartoner

Secondary Packaging

Infeed Dual Belt Conv. BeltRobot 1 Robot 2 Robot 3

Infeed Dual BeltConveyor Belt

Robot 1

Robot 2Robot 3


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Fulfilling national and international standards

The PackML state model can also be created without the template and Equipment Modules, using Function Blocks from the AFB library.

Every step of the PacDrive programming con-cept is based upon standards and simplifi es certifi cation of the products produced according to such standards: All libraries are based upon the PLCopen and IEC 61131-3 guidelines. All AFBs and Equipment Modules are documented and tested in practice, a basic requirement for high software quality and rapid commissioning. They also make FDA certifi cation of machines much easier.

The template is also strongly infl uenced by standards. For example, the available operating modes meet ISA 88.05 (PackML) requirements. The template is an important component for creating machine programs based upon the PackML standards, and also facilitates compli-ance with the Weihenstephan standard.

PackML state model included:Designing operating modes with the template fulfills ISA 88.05 require-ments


SCSC

SC SC

SCStart SC SC

SC

SC

Reset

Suspend

Hold

Un-Sus-pended

Reset StopAbort

Clear

Un-Hold

SC

Idle

Resetting

Stopped

Starting

Un-Holding

Un-Suspending

Stopping

Execute

Held

Suspended

Clearing

Completing

Holding

Suspending

Aborted

Complete

Aborting

Extensive Function Block libraries, including PLCopen Enhanced software

quality thanks to off-the- shelf software (FDA, cGMP, 21CFR Part 11-compliant) Template programming

for modular, reusable software Compliance with OMAC

and Weihenstephan helps to ensure machine and line standardization


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Integrated drives, network – standardized for e

Quick interconnects and hybrid cables for signa and power level, automatic network configuration, and diagnostic functions: iSH Series servo modules with in-tegrated onboard drive electronics are more than just compact drives. The drive and network solution to-gether form a true plug-and-play solution that enables modularity and generates tangible cost advantages

Integrated Servo Motors

Plug-and-play solution:Intelligent servo modules, flexible networking, and a shared power supply are combined in servo drives with holding torques of 1.1 to 12.5 Nm


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king, and power easy design and operation

Integrated Servo Motors >> >>

Flexible network topologies 70% shorter cable

lengths 90% less control cabinet

space required for the servo drive solution 90% less wiring required

in the control cabinet 50% less cable instal-

lation required on the machine frame Communication

between sensors and actuators over the motion network with option modules


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Servo drives take up less cabinet space:iSH Series servo modules reduce the control cabinet space required for servo drives by up to 90%

Integrated Servo Motors >>

Smaller control cabinets - less wiring and installation work

Flexible networking

iSH Series servo modules reduce the control cabi-net space needed for servo drives by up to 90%: Conventional servo drives are eliminated, the only components remaining in the control cabinet are the automation controller and a shared power supply for up to 25 servo modules. In many cases, this eliminates the need for cabinet fans or air conditioning. Eliminating the servo drives also reduces cabinet wiring by up to 90%, for a signifi cant reduction in installation cost.

iSH Series servo modules use a fl exible approach to cabling, consisting of pre-terminated hybrid cables and distribution boxes. The specifi c ap-plication determines whether this will be a line structure, a tree structure, or a mixed design. One two-sided pluggable cable is suffi cient to connect each servo module to the networking solution. Only one cable is connected to the control cabinet

(for up to 25 servo modules). The network itself is confi gured as a plug-and-play solution. Com-pared to classical servo solutions, this reduces the required cable by up to 70%, producing tan-gible savings. It also decreases the labor required for wiring the servo solution in the machine frame by approximately 50%.

Distribution BoxDB-5





iSH servo module iSH servo module iSH servo module

PacDrivecontroller

Power Supply PS-5

Smaller control cabinet, greater flexibility

Up to ’25 iSH servo modules per PS-5 power supply

Up to 70% less cabling: Flexible networking topol-ogy, thanks to pluggable hybrid cables and distribu-tor boxes


Experience shows that sensors or actuators are typically mounted in the immediate vicin-ity of servo drives. With the I/O option module for iSH servo modules, up to eight sensors or actuators can communicate with the controller via the motion network, eliminating the need for a dedicated device bus. Up to two I/O can be connected directly to the servo module, and DIO-4 I/O interconnect modules expand the number of connections. All eight connec-tions can be confi gured as inputs or outputs, depending upon requirements.

Sensor/actuator communication:With an I/O option module mounted to the iSH servo module, up to eight sensors or actuators can communi-cate with the automation controller over the motion bus without the need for a separate field bus.

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Integrated Servo Motors >> >>

DIO-4

Up to 8 I/O with 2 DIO-4 modules

DIO-4iSH servo module with option module

Technical Data

Device communication over the motion network

Holding torque of 1.1 to 12.5 NmiSH servo modules are available in fl ange sizes of 70, 100, and 140 mm, covering a holding torque range of 1.1 to 12.5 Nm. All models are software-compatible with one another and with MC-4 Series servo drives. All servo modules can

be equipped with optional I/O modules. Additional options include the integration of a holding brake, a feathered key groove, a multi-turn encoder with electronic name plate and an IP65 shaft seal.

High power density:Thanks to their com-pact design and smooth surfaces, the iSH Series intelligent servo modules have space requirements comparable to standard servomotors.

Types

Standstill torque

M0 [Nm]

Peak torque

Mmax [Nm]

Rotor inertia

JM [kgcm²]

Rated speed

nN [min-1]

iSH-070 / 60011 1,1 3,5 0,25 6000

iSH-070 / 60017 1,7 7,6 0,41 6000

iSH-070 / 60022 2,2 8,7 0,58 6000

iSH-100 / 30025 2,5 9,6 1,40 3000

iSH-100 / 30044 4,4 18,3 2,31 3000

iSH-100 / 30058 5,8 28,3 3,22 3000

iSH-140 / 30075 7,5 27 7,41 3000

iSH-140 / 15085 8,5 27 7,41 1500

iSH-140 / 20125 12,5 55 12,68 2000

Constantly updated data available at www.elau.de/servodrives



32

Servo drives for installation in control cabinets

Universal MC-4 Series compact servo drives can be used for both rotary and linear servo motors as well as torque motors. They cover a wide performance range with a small number of individual models. All models are software-compatible with one another. MC-4 servo drives are also compatible with iSH drive systems, which permits mixing of standard servo motors and iSH servo modules in a synchro-nized multi-axis system.

Servo Drives

Fewer models:With five models in only three form factors, the MC-4 Series covers a power range of 1.1 to 34.5 kVA.


33

Wide supply voltage range (from 380 VAC to 480 VAC, 3 phase) Integrated power supply Max. 34.5 / 69 kVA

output Automatic motor

detection Inverter Enable

(according to IEC 61508:1998, EN/ISO 13849-1:2006) Up to 250% overload Simplified replacement

part logistics due to minimized number of types

The fully digital MC-4 servo drives are self-contained rack-mounted units consisting of a power supply, amplifi er, brake bleeder, and power fi lter for one axis. Depending upon the type, MC-4 servo drives produce between 1.5 and 50 amps of continuous current. DC bus sharing is possible for multiaxis solutions.

MC-4 servo drives communicate with the controller via SERCOS II over fi ber optic cable, which also makes them suitable for remote installation. They process signals from single and multi-turn encoders. All models have an electronic name plate and are automatically confi gured with the connected motor and the specifi ed controller parameters during initial commissioning or replacement.

Servo Drives >>

Technical Data

Type MC-4/01 MC-4/03 MC-4/10 MC-4/22 MC-4/50

Rated current Aeff 1,5 3 10 22 50

Peak current Aeff 3,75 7,5 25 55 125

Rated power [kVA] 1,1 2,1 6,9 15,2 34,5

Supply voltage [V] AC 342 ... 528

Supply frequency [Hz] 48 ... 62

Control voltage [V] DC 20 ... 30

Bleeder resistance integrated

Power supply and power fi lter integrated

Safety functions* Safe Stop 1 (SS1)** and Safe Torque Off (STO)** via Inverter Enable

Motion bus SERCOS interface

Width [mm] 69 69 69 124 312

Depth [mm] 230 without connector/ 260 with connector

Height [mm] 240 without mounting brace / 310 with mounting brace

Protection class IP 20

Ambient temperature [°C] +́5 ... + 45; (...+55)

Excess voltage category KIII, T2 (DIN VDE 0110)

Excess voltage resistance Class 1 (DIN VDE 0160)

Degree of radio interference Class A EN 55011 / EN 61800-3

Certifi cations CE / cULus CE

Constantly updated data available at www.elau.de/servodrives


MC-4Versatile with high peak current capability

* according to IEC 61508:1998, EN/ISO 13849-1:2006** according to IEC 61800-5-2:2007


Rotary and linear servo motorsModern, high-speed production machines require highly dynamic and pre-cise AC servo motors with a wide power range. Brushless, overload-protect-ed servomotors with high resolution encoders as well as torque and linear motors offer solutions for a variety of applications. All of the rotary and linear servo motor types can be operated by MC-4 servo drives and thus integrated into synchronized multiaxis systems over the SERCOS interface.

Servo Motors

34

Low rotor inertia:SH Series AC servo motors meet the highest perfor-mance requirements


35

Compact design and high power density thanks to salient pole windings Low rotor inertia Electronic name plate Optional stainless steel

shafts, shaft seals, integrated brakes Triple overload capacity Optional exterior fan

cooling or water cooling for better capacity utilization Unpainted housing upon

request for food applications Optional IP 67 rating

for harsh environmental conditions Single-turn and multi-

turn absolute value encoder

Available in fi ve fl ange sizes, from 55 mm to 205 mm, and and a wide range of rated torques, SH motors are ideal for almost every application. Because of their low inertia com-pared to other servomotors, SH motors deliver impressive dynamics.

Despite their power, they are exceptionally compact thanks to salient pole winding technol-ogy. The sleek housing is equipped with plug connectors that can be rotated 300°. The elec-tronic name plate makes the motors an integral component of the PacDrive automation system.

Servo Motors >>

Technical Data

Subject to modificationsConstantly updated data available at www.elau.de/servodrives

Motor

Holding torque Ambient cooling

M0 [Nm]

Holding torqueFan cooled

M0 [Nm]

Holding torqueFlange water

cooled

M0 [Nm]

Peak torque

Mmax [Nm]

Rotor inertia

JM [kgcm²]

Rated speed

nN [min-1]

SH 055/80005 0,5 1,5 0,059 8000

SH 055/80009 0,8 2,5 0,096 8000

SH 055/80012 1,2 3,5 0,134 8000

SH 070/60010 1,4 3,5 0,25 6000

SH 070/60020 2,2 7,6 0,41 6000

SH 070/60030 3,1 11,3 0,58 6000

SH 100/50030 3,3 4,3 5,3 9,6 1,0 5000

SH 100/40060 5,8 7,5 8,9 18,3 2,31 4000

SH 100/40080 8,0 11,0 12,0 28,3 3,22 4000

SH 100/30100 10,0 14,2 13,8 40,5 4,22 3000

SH 140/30120 11,1 15,6 17,1 27,0 7,41 3000

SH 140/30200 19,5 30,8 29,8 60,1 12,68 3000

SH 140/30270 27,8 42,4 41,4 90,2 17,94 3000

SH 140/30330 33,4 54,8 48,9 131,9 23,0 3000

SH 205/30360 36,9 46,9 110 71,4 3000

SH 205/20650 64,9 87,2 220 129 2000

SH 205/20900 94,4 124,5 330 190 2000

SHServo motors in five flange sizes


36

Peak torque is 4 times rated torque Single-turn and multi-

turn high resolution encoders Robust terminal box with

plug-in connectors IP 64/65 protection

rating Optional EExp rating,

stainless steel shafts, shaft seals, integrated brakes Electronic name plate Optional IP 67 rating

for harsh environmental conditions

Servo Motors >>

The SM series of AC servo motors combine fl exibility with a high level of precision. All models are equipped with high resolution encoders providing one million steps per revolution. The motors, which are equipped with electronic name plates and come in three fl ange sizes and various stack lengths, cover a holding torque range of 1.1 to 57 Nm.

Technical Data

Motor

Holding torque Ambi-ent cooling

M0 [Nm]

Holding torqueFan cooling

M0 [Nm]

Peak torque

Mmax [Nm]

Rotor inertia

JM [kgcm²]

Rated speed

nN [min-1]

SM 070/60010 1,1 - 4,7 0,48 6000

SM 070/60020 2,0 - 7,7 0,79 6000

-

SM 100/50030 2,6 - 10,0 2,28 5000

SM 100/40050 4,8 8,0 16,0 3,64 4000

SM 100/40080 8,0 13,0 30,0 6,54 4000

SM 100/30080 8,0 13,0 27,0 6,54 3000

SM 140/30120 11 17,0 45 10,3 3000

SM 140/30210 20 35 76 18,1 3000

SM 140/30290 29 48 103 24,9 3000

SM 140/30370 36 57 126 33,1 3000

Low rotor inertiaSM series AC servo motors feature high peak torque capability

SMServo motors in three flange sizes



38

Servo Motors >>

Capable of extremely high torque without gear reduction Minimal length Hollow shafts possible

Technical Data

Torque Motors:In addition to standard torque motors, appli-cation-specific custom designs are available

Torque motors can also be used in PacDrive automation solutions. Standard torque motors and application-specifi c custom designs can be driven by standard MC-4 servo drives with HIPERFACE® encoder feedback. Torque motors can therefore be totally integrated into synchro-nized multiaxis systems while maintaining their full functionality.

MotorHolding torque

Fan cooling

M0 [Nm]

Peak torque

Mmax [Nm]

Rotor inertia

JM [kgcm²]

Rated speed

nN [min-1]

TM 250/041 32 96 170 400

TM 250/042 62 186 265 400

TM 250/043 92 276 360 400

TM 250/044 120 360 455 400

TM 300/021 100 300 570 250

TM 300/022 150 450 755 250

TM 300/023 200 600 940 250

TM 300/024 240 720 1125 250

TMTorque Motors



Continuous forces of 150 to 3750 N Minimal mechanical wear High precision thanks

to tight tolerances by design Can be operated with or

without water cooling

Technical Data

The LM series consists of 12 three-phase linear motors in three different stator widths and with various secondaries. The motors can be oper-ated with Hiperface TTK 70 linear encoders by MC-4 servo drives. Depending upon the type, they can generate continuous force of 150 to 3750 N. The motors can be cooled by convec-tion or water when generating higher continu-ous force. The offset arrangement of the poles minimizes residual torque. All of the motor parts are potted with cast epoxy resin insula-tion and fulfi ll IP 55 requirements. An integrated PTC thermal fuse protects the motors from overload.

39

Servo Motors >>

LMLinear motors

Constantly updated data availableat www.elau.de/servodrives

Max. 4 m length – Subject to modifications

MotorContinuous force

Convection cooled

Fn [N]

Continuous forceWatercooled

Fn [N]

Peak force

Fmax [N]

Maximum speed

Vmax [m/s]

LM 030/101 150 300 400 10

LM 030/102 300 600 800 10

LM 030/103 450 900 1200 10

LM 050/061 280 500 650 6

LM 050/062 560 1000 1300 6

LM 050/063 840 1500 1950 6

LM 050/064 1120 2000 2600 6

LM 075/041 440 750 1000 4

LM 075/042 880 1500 2000 4

LM 075/043 1320 2250 3000 4

LM 075/044 1760 3000 4000 4

LM 075/045 2200 3750 5000 4

Linear motorsHigh dynamic direct drive technology


40

Automation components on the field busPositioning solutions, variable frequency drives, and motor protection com-ponents communicating via field bus supplement the automation solution to meet application needs. Profibus, CANopen and DeviceNet connections and I/O are available for PacDrive drives. Various IP 20 and IP 67 rated I/O configurations are available.

Field Bus Interfaces


41

40% less wiring required 25% less cabling

required Three different motor

technologies enable optimal adaptation to each application Can be used with

popular field buses Simple installation and

commissioning Integrated safety thanks

to safety function Safe Torque off

(STO according to IEC 61508:1998, EN/ISO 13849-1:2006)

The Lexium line of integrated drives combines the motor, positioning control, power electronics, fi eld bus, and the “Safe Torque off” (STO according to IEC 61508:1998, EN/ISO 13849-1:2006) safety function in a single assembly. Three variants are available:

The Lexium ILA, with a servo motor, delivers a high degree of fl exibility. It generates high torque even during acceleration. Different winding types are available for application-specifi c requirements.

The Lexium ILE, with an electronically com-mutated motor, offers maximum fl exibility. The 3-phase synchronous electronic electronically commutated brushless DC motor has a high holding torque of up to 8 Nm (with spur l gear drive), often eliminating the need for a holding brake. The integrated electronics communi-cate absolute position as to the automation controller.

The Lexium ILS, with a step motor, is the most precise of the three. The 3-phase step mo-tor generates high torque at low speeds. This often eliminates the need for gear reduction, permitting space saving direct drive solutions. The Lexium ILS is the optimal solution for high resolution positioning with good synchroniza-tion. Commissioning involves minimal effort -- the user merely needs to adjust the power supply.

All integrated Lexium drives can communicate via Profi bus DP, CANopen, or DeviceNet.

Field Bus Interfaces >>

Technical Data

Motor

Speed range[rpm]

(direct drive)

[1/min]

Continuous torque

(direct drive)

[Nm]

Peak torque

(direct drive)

[Nm]

Encoder Holding brake

Optional gearing

ILA servo motor drive < 7500 < 0,26 < 1,62 High-resolution encoder (16384 increments)

Yes Planetary gear unit (Gear ratios from 3:1 to 40:1)

ILE EC motor drive < 5000 < 0,24 < 0,80 Hall sensors No Cylindrical and planetary gear unit (Gear ratios from 18:1 to

115:1)

ILS step motor drive < 2000 < 6 < 6 With or without index pulse encoder (optional)

Yes Planetary gear unit (Gear ratios from 3:1 to 8:1)

Lexium® ILxIntegrated Positioning Drives

Subject to modificationsFurther information available at www.schneider-electric.com

Lexium integrated drives: Three variants with three different motors


42

Wide performance range Integrate easily into

PacDrive automation system CANopen integrated,

additional field bus options available for ATV 71 variable frequency drive Technical Data


The Altivar family of variable frequency drives offers optimal price and functionality for every speed control application. The Altivar 312 is ideal for simple machines with a power range of up to 15 kW. For more complex machines with higher performance, the Altivar 71 with its power range of 0.37 to 1300 kW is the right solution.

The Altivar 312 and 71 models are suitable for applications such as packaging, transportation, conveyors, positioning systems, or textile ma-chines. This makes them ideal for PacDrive au-tomation solutions. Time saving Function Blocks for integrating these frequency drives

are provided in PacDrive software library. Both models can communicate via Mod bus or CANopen, and both can be connected to Profi -bus, Ethernet/IP, and DeviceNet via integrated communication cards.

Altivar: Variable frequency drives for both simple and com-plex machines; pictured are the ATV 71 and ATV 312 models

Altivar® 312/71Variable frequency drive

Altivar type

ATV 312 ATV 71

Power range in kW(50...60 Hz power supply)

Single-phase 200...240 V 0,18…2,2 0,37…5,5

3-phase 200…240 V 0,18…15 0,37…75

3-phase 380…480 V – 0,75…1300

3-phase 380…500 V 0,37…15 –

3-phase 525…600 V 0,75…15 –

Output frequency in Hz 0,5…500 1…1600 Hz bis 37 kW, 1…500 Hz von 45...500 kW

Short-term overload moment in %of the rated motor moment

for 2 s 170-200 220

for 60 s 170-200 170

Communicationintegrated Modbus, CANopen Modbus, CANopen

optional Ethernet TCP/IP, DeviceNet, Profi bus DP Ethernet TCP/IP, Modbus Plus, Profi bus DP, Uni-Telway, DeviceNet, etc.



43

Plug-and-play without encoder systems and commissioning software. Excellent

synchronization High torque even at

low rotational speeds Integrated safety

functionality: (STO according to IEC 61508:1998, EN/ISO 13849-1:2006)


Technical Data

Lexium SD328 step motor drives:Compact plug-and-play solutions with minimal space requirements in the control cabinet

The Lexium SD328 step motor drive is a powerful positioning solution for communication via Profi bus, CAN, and CANopen. The different variants are designed for holding torques of 17 to 19.7 Nm. The safety function “Safe Torque Off” (STO according to IEC 61508:1998, EN/ISO 13849-1:2006) is already integrated in the device. Drives are available in up to 6.8 A. The SD328 is suitable for a power supply with 1~115 VAC and 230 VAC (50/60 Hz). A power fi lter is integrated, and current is reduced automatically at zero speed. The SD328 can also be supplied with motion monitoring on request.

3-phase step motor typeStep motor drive

115 V/230 V

Type

Holding torque at zero speed

[Nm]

Maximum torque

[Nm]

Maximum speed (RPM)

[1/min]

BRS368/50 LWx

SD328 x U25 (2,5 A)

1,7 1,5 2000

BRS397/50 LWx 2,3 2,0 2000

BRS39A/50 LWx 4,5 4,0 2000

BRS39B/50 LWx 6,8 6,0 2000

BRS3AC/50 LWxSD328 x U68 (6,8 A)

13,5 12,0 2000

BRS3AD/50 LWx 19,7 16,5 2000

Lexium SD328Step motors on the field bus



44

Advantys OTB

Advantys FTB

Advantys STB

Advantys FTM


TeSys U motor starters are an economical combination of motor overload switch and power protection in one device. Basic devices for direct or reversing starters (each available in 12 A and 32 A variants) combined with one of the six available motor control units create a complete, fl exible solution. This multifunctional-ity saves space in the control cabinet, reduces the need for cabling, and simplifi es logistics by reducing the number of components. Software Function Blocks also make it easier to integrate into PacDrive solutions.

The Advantys family of products offers solu-tions for a variety of needs: Advantys OTB is an economical distributed I/O solution with an IP 20 protection rating, designed especially for small, compact machines. Advantys STB - also with an IP 20 protection rating - is a distributed, open I/O system that can be expanded to a maximum of 32 modules.The Advantys FTM and FTB series offer IP 67 rated distributed I/O technology. The FTB series includes compact I/O units in various I/O combinations, with plastic or metal housings. By contrast, the FTM system is fl exible enough to combine any number of I/O submodules as needed to create a customized I/O unit.Both Advantys series have integrated channel and module diagnostics, and are compatible with sensors/actuators having an integrated diagnostics function (DESINA).

TeSys U:Reduced space and cabling thanks to the combination of motor pro-tection switch and power protection

Distributed I/O technology, IP 20 rated:Advantys OTB offers an economical solution for small, compact machines. With I/O units consist-ing of up to 32 individual modules, Advan tys STB is the universal solution

Distributed I/O technology. IP 67 rated:Cost effectiveness is the determining factor in choosing between the FTB series modules and the customizable FTM design

TeSys® UMotor starter technology

Advantys™Distributed I/O systems


46

Safety functions for the entire machineWith a broad range of components for safe* signal recording, signal pro-cessing and dialog, comprehensive safety designs can be implemented in PacDrive automation solutions. The resulting safety functionalities meet current standards.

Functional Safety

The Preventa™ product line of safety control-lers and components includes a large selection of compact safety controllers and components, compact distributed safety I/O modules, and modular safety components. The devices’ safety level fulfi lls requirements up to SIL 3 (Safety Integrity Level) in accordance with IEC 61508:1998 or IEC 62061:2005 and PL e (Performance Level) in accordance with EN ISO 13849-1:2006 or Category 4 according to EN 954-1:2004.

For small to midsize applications, for example, the Preventa XPS-AV safety module enables integration of the ´Safe Stop 1´ (SS1 )** and ´Safe torque off´ (STO)** functions in PacDrive automation systems. The safety component is suitable for monitoring up to six positions or emergency stop switches. It has three status outputs and a number of diagnostics options. Sixteen different times can be set.

The BBH SMX Series modular safety controls can be used if the ´Safe Stop 2´ (SS2)**, ´Safe Operating Stop´ (SOS)** and ´Safely-Limited Speed´ (SLS)** functions are also required for individual servo axes. The SMX safety control-lers have an extremely fast response time of 4 ms. Interface modules for CAN or Profi bus DP as well as an I/O expansion are available for both SMX variants. The safety functions, which can be implemented in combination with MC-4 servo drives, meet the requirements of SIL2 and PL d/Cat. 3.

Safe* signal processing:The Preventa line of safety controllers and compon-ents offer scalable logic and I/O functionality

Signal processing

* according to IEC 61508:1998, EN/ISO 13849-1:2006 ** according to IEC 61800-5-2:2007


47

Functional Safety >>

Preventa XPS-AV: Safety component for creating safe automation solutions with the SS1 and STO safety functions

Modular System:The SMX 11 safety switch devices (capable of moni-toring one axis) or SMX 12 (capable of monitoring two axes) can be supple-mented with field bus interface modules and an I/O assembly

Helping to ensure secure recording of signals, the Preventa program offers safety position switches, coded magnetic safety switches, a coded magnetic safety system, safety light curtains, and safety switch mats. The range of individual products included in this product series is suitable for a wide range of tasks, including the securing of doors, covers, and protective zones.

The Safe Dialog components of the Preventa product line offer a wide spectrum of solutions for safe operation and for triggering safety related responses. They cover the entire range of possibilities, from circumvention resistant emergency stop buttons, two-hand control con-soles, foot operated and pullcord emergency switches, to enabling switches and operating mode switches.

Safe signal recording:With pullcord emergency switches, emergency stop buttons, enabling switches or foot switches as well as two-hand control units, the program includes all com-mon solutions for safety related operating devices

Safe dialog:With pullcord emergency switches, emergency stop buttons, enabling switches or foot switches as well as two-hand control units, the program includes all com-mon solutions for safety related operating devices

Pac Drive with

Function ** Preventa XPS-AV 1113Z002 SMX 11 bzw. SMX 12

Safe Torque Off (STO) ✓ ✓ Basic safety functions (Suggested schematic available)Safe Stop (SS1) ✓ ✓

Safe Operating Stop (SS2, SOS) - ✓ Enhanced safety functions (Suggested schematic available)Safely-Limited Speed (SLS) - ✓

Safe Direction (SDS) - ✓

Enhanced safety functions

Safely Limited Position (SLP) - ✓

Safe Maximum Speed (SMS) - ✓

Safely Limited Increment (SLI) - ✓

Safely Monitored Shutdown (SMD) - ✓

Safe I/Os (S IO) - ✓

Overview:Safety functions that can be performed by Preventa XPS-AV and BBH SMX 11 or SMX 12

Signal recording

Dialog

Further information available at www.schneider-electric.com


48


The ´Safe Stop 1´ (SS1 )** and ´Safe Torque off´ (STO)** safety functions can be implemented with the Preventa XPS-AV safety module for all PacDrive servo motors and drives as well as for Lexium drive and positioning solutions and for Altivar variable frequency drives on a fi eld bus. The SS1 and STO functions are required for machine shutdown in an emergency (emergency stop), Stop Category 0 and 1 according to EN 60204. A suggested schematic and a test certifi cate are avail-able for Preventa XPS-AV safety solutions.

Basic Safety Functions SS1 and STO for PacDrive automation solutions

Safety STO, SS1

Suggested schematic and test certificate available Cost-optimized solution

with integrated safety features Wide range of

diagnostic options


Fieldbus e.g. , Profibus, Ethernet/IP CAN

Scalable HMI Scalable Controller

Motion Logic Control

Motion bus SERCOS

IT/HMI

Logic Motion


49


If the safety functions ´Safely-limited Speed´ (SLS)**, ´Safe Stop 2´ (SS2)**, and ´Safe Operat-ing Stop´ (SOS) are required in addition to the safety functions SS1 and STO for individual servo axes, these can be implemented with the safety switch devices found in the BBH SMX series. Safe Operating Stop can also be created with explicit deceleration rate monitoring. Thanks to the rapid 4 ms response times of the SMX11 and SMX12, it is possible to achieve servo drive responses of less than 20 ms to a triggering event. If necessary, users can monitor multiple protection circuits if emergency shutoff functions and protective doors affect different drives. A suggested schematic is also available for safety solutions with SMX assemblies.

Advanced safety functions SS2, SOS, and SLS for PacDrive automation solutions

Faster response to a triggering event (20 ms) Deceleration rate

monitoring at SS1 Monitoring of multiple

safety circuits Less cabling required

thanks to field bus connection Suggested schematic

available


Fieldbus e.g. , Profibus, Ethernet/IP CAN

Scalable HMI Scalable Controller

Motion Logic Control

Motion bus SERCOS

Safety STO, SS1

Advanced Safety STO, SS1, SS2, SOS, SLS

IT/HMI

Logic Motion

** according to IEC 61800-5-2:2007


50

Robotics IntegrationThe integration of robotics into the machine control solution is one of the outstanding aspects of the PacDrive automation system. On the software side, the integration of robots is made simpler by an IEC-compliant library with Equipment Modules (Ems) and Application Function Blocks (AFBs) for motion programming and transformation to all commonly used kinematics. Thanks to the availability of complete robot arm mechanics, there is also no longer any need to develop customer-specific kinematics or to integrate third-party products. This permits even faster creation of robot-enabled machine designs.

Robotics Solutions

Infeed

Robot

Dual BeltConveyor Belt

Robot

Robot


51

Robotics Solutions >>

Cartoner

Robot

Grouping

Motion Bus: SERCOSField Bus: e.g. Profibus DB

Scalable ELAU Controllerwith Motion/Logic Control

Dual BeltInfeed Conveyor BeltIn/Out Robot Robot

The PacDrive system supports an almost unlimited variety of kinematic confi gurations, allowing robotics to become an inte-gral part of a machine’s automation architecture. The high performance C400 and C600 automation controllers are capable of synchronizing up to 16 or 99 axes respectively into a real-time multiaxis system. From the controller perspective, there-fore, a robot is reduced to a motion control system with a corresponding number of servo axes, which can operate under demanding real-time conditions. In this way, the controller can manage one or more robots in addition to other machine functions within an IEC 61131-3-compliant program.

Integral automation structure components

Easy software integration thanks to AFB and EM libraries

Transformation modules for PacDrive and standard kinematics

The integration of robots into the PacDrive automation solution software almost completely eliminates complex software algorithms. The robots are mapped onto a software module, which is then inserted into modular, IEC-61131-3-compliant program structures, just as with other mechatronic machine modules. This structure is based upon library Function Blocks that are parameterized by the user or “fed” with motion data in the form of a program or a table. Once the motion paths have been defi ned, parameters can be specifi ed in order to limit the acceleration forces that act on the transported product. The option to specify blending parameters provides further potential for optimizing the motion paths. The controller performs all of the other functions, up to actuation of the actual robot axes, based upon library Function Blocks.

In the PacDrive robotics solution, motion program-ming and its transformation to robot kinematics are separate processes. This means that the robot kinematics can be selected independently of the generated motion program. Regardless of whether the project uses standard kinematics developed by the customer, by third-party sup-pliers, or PacDrive mechanics (Delta-2, Delta-3, and portal kinematics are currently available), the appropriate transformation module adapts the selected solution to the motion program.

Integration of robots in the automation architecture:Depending upon the number of axes, kinematics, speed and other requirements, one C600 controller, for ex-ample, can control between six and 30 robots, each with three axes.

One controller can control machines and multiple robots Software integration

using Function Block library Fully integrated

IEC 61131-3-compliant software, no additional programming tools Easy access to process

parameters One development

environment for machines and robots Transformation modules

for popular robot kinematics: Gantry, Scara, Portal, Articulated, Delta


IT/HMI

Logic Motion


52


Delta 2 Delta 3

Gantry Portal

Scara Articulated

In addition to trans-formation modules mapped to these kinematics, a univer-sal transformation module is also avail-able for custom de-signed or third party kinematics, so that various robots can be controlled with ELAU controllers

PacDrive robot mechanics -- P4 (upper right), MAX R (center-right), MAX P (center left) or custom designed kinematics:Availlable transformation modules incorporate all typical kinematics into the controller software


53

* including rotational axis in the R version

Type P4s-F / P4s-R P4i-F / P4i-R

Load capacity 1,5 [kg]

Speed max. 10 [m/sec]

Max. acceleration at 1kg 100 [m/sec2]

Max. acceleration at 1.5kg 75 [m/sec2]

Number of axes 3 (4*)

Repeatable position accuracy +/- 0,1 [mm]

Work envelope height 225 [mm]

Work envelope diameter 1200 [mm]

Work envelope rotation* Unlimited

Protection rating IP 65 –

Constantly updated data available at www.elau.de/robotics

Everything fi ts together: Robot mechanics, servo systems, and robotics library provide a ready-to-use solution. In addition, complete packages, including engineering, can ac-celerate the integration of robotics into an application.

The P4 delta-3 robot (P4s-F standard version), featuring full stainless steel construction, is designed for pick & place applications. The software includes a preprogrammed interface for integration of the most commonly encoun-tered vision solution. The P4 can be equipped with an optional rotational axis (P4s-R). The P4 robot arm is driven by conventional motors with cabinet-mounted servo drives (P4s-F or P4s-R) or by intelligent servo modules with integrated control electronics (P4i or P4i-R). Thanks to their IP 65 rated washdown confi guration, the P4s-F and the P4s-R are also suitable for hygienic environments.

P4Complete robotics packages for Delta 3 kinematics

P4 delta-3 robot kinematics:With standard motors, available in washdown configuration up to IP 65



54

The modular linear motion system consists of basic elements and complete solutions for a variety of 1, 2, and 3 dimensional motion tasks. Thanks to its fully modular structure, all elements can be confi gured as needed. The length and stroke of each axis system is indi-vidually determined.

Portal axes in various sizes, with timing belt drive or spindle drive as desired, can move loads of up to 100 kg. The structural elements of these linear tables are extremely rigid, and the overall assembly has very compact dimen-sions. Cantilever axes with round rods or an extruded aluminum profi le design are particu-larly well suited for limited spaces. Thanks to the fi xed motor and moving body of the axis, cantilever axes can move fl exibly into the work envelope.

Double-axis systems move loads with great fl exibility and speed across distances of up to 5 1/2 meters. They also serve as a basis for complete solutions for multidimensional motion tasks:

The MAX P linear positioner, a combination of double-axis system and cantilever axis, moves up to 50 kg with a high level of precision.

The MAX R portal robot with two servo axes and the MAX R 3 with three servo axes are the top-of-the-line designs for the modular linear motion system. A rotational axis can also be integrated as an option.

PacDrive offers complete or adaptable trans-formation modules for all conceivable variants of up to fi ve axes for integrating robotic solu-tions into a machine’s program structure.

Linear MotionSingle and multiaxis systems for linear motion

Portal axes:Left: PAS S (spindle drive), center: PAS B (timing belt drive) and right: TAS linear table

MAX P linear positioner:The combination of double axis system and cantilever axes can be mounted both above and below the workspace.

Cantilever axes:Left: CAS (round rod axis), right: CAS 4x (profile axis)

MAX H double-axis system:Designed for positioning over long distances



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Further information available at www.schneider-electric.com

Technical Data

Single-axis systems

PAS B PAS S TAS CAS

Portal axis Portal axis Linear table Cantilever Telescoping axis

Design Profi le Round rod Profi le

max. load [kg] 100 100 150 50 18 35

max. stroke [mm] 5500 3000 1500 1200 500 2400

Positioning speed[m/s]

8 1,25 1 5 2 5

Guides Roller bearings/ball bearings

Ball bearings Recirculating ball bearings

Roller bearings/Recir-culating ball bearings

Recirculating ball bearings

Roller bearings/Recir-culating ball bearings

Version Profi le Round rod Profi le

Drive element Timing belt Spindle Spindle Timing belt Timing belt

Double-axis and Multi-axis systems

MAX H MAX S MAX P MAX D MAX R2 MAX R3

Double-axis system Linear positioner Portal robot

Axes 1 1 2 2/2 2 3

max. load [kg] 250 300 50 2/5 137 50

max. stroke in x [mm] 5500 5500 5500 300/700 5500 5500

max. stroke in y [mm] – – – – 1500 1500

max. stroke in z [mm] – – 1200 150/300 – 1200

Mechanics packages available for delta-3 and portal kinematics Fully compatible

components Support and service

from a single source for the entire automati on solution Complete package of

mechanics and engineering support available upon request


Portal robot MAX R2 or R3:This robot is mounted over the work envelope as either an x-y or an x-y-z unit, depending upon requirements.


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Recording, notification,and power distribution and switchingSchneider Electric offers an extensive product line of standard and auxiliary electrical equipment for machine construction, production lines, and entire production facilities: Power supplies, mounting and cabling systems for low voltage and medium voltage applications, control and signalling units - A small excerpt from our portfolio demonstrates the wide variety of solutions we offer. All of these are part of a larger system in which every component is compatible.

Electrical Components


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Electrical Components >>

Control cabinets and enclosures:A wide range of sizes, materials, and installation accessories

Harmony™ control and control and signalling units:Signaling technology as well as a series of lighted and unlighted pushbut-tons, switches, and much more

OSIconcept™ recording systems and sensors: Complete families of sensors for optoelectronic, inductive, or ultrasound recording as well as positioning switches, in both standard versions and application-specific solutions

Ositrack®:An open RFID solution that allows users to select the data medium, all data media in a solution can be automatically configured


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Canalis® rail distribution system:A comprehensive system for distribution of lighting and electrical power in all types of structures, from 20 to 4000 A

Phaseo®:Transformers and power supplies for various input and output voltages, watt-ages, and applications

GV3 motor protection switch:Triggers at motor currents of 9 to 65 A, with ther-momagnetic or magnetic triggers if needed

Compact NSX circuit breaker:Enhanced measurement and communication functions starting at 16 A


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Switchgear and controlgear systems: Switchgear and control-gear systems for individual solutions; shown at right: Okken in withdrawable-unit design up to 7300 A

Altistart® 01 und 48:Soft starters for AC induction motors and three-phase AC induction motors for 0.18 to 630 kW, ideal for use in combina-tion with Altivar ATV 312 and ATV 71 frequency converters

Multi 9® line circuit breaker: Line and device protection as well as monitoring in many variants


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Contact

Please note that the information ex-

pressed in this document is intended

for product description purposes

only and is not legally binding. The

information is subject to change

without further notice. If details from

this document become express terms

of a contract concluded with ELAU,

the details from this document referred

to in the contract are intended only for

the specifi cation of the subject of the

contract.

ELAU is a registered trademark of Sch-

neider Electric and/or its affi liates in the

United States and/or other countries.

Other marks used herein may be the

property of their respective owners.

© 2009 Schneider Electric.

All rights reserved.

Further Information is available fromwww.elau.com

ELAU GmbHHeadquartersDillberg 12-1697828 MarktheidenfeldGermanyPhone +49 9391 606-0Fax +49 9391 [email protected]

ELAU North America+1 847 [email protected]

ELAU UK+44 1908 [email protected]

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ELAU Switzerland+41 62 [email protected]

ELAU BeNeLux+31 40 2350 [email protected], [email protected], www.elau.be

ELAU China+86 512 [email protected]


ELAU Automation Solution for Packaging and Production Brochure

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